Singleline Systems for Commercial Vehicles - Mekol · for use on vehicles carrying hazardous goods ... Singleline Systems for Commercial Vehicles for grease up to ... 4. brake shaft

Single�line Systems for Commercial Vehicles1-9420-US

�� Cut wear and tear�� Reduce downtimes�� Lower maintenance costs

with automatic lubrication

www.vogelag.com

For grease up to NLGI grades 000, 00 or 0

Single�line Systems for Commercial Vehicles for grease up to NLGI grades 000, 00 or 0 1�9420�US 3

worldwide

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Table of contents

Page

Alphabetical index of subject . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 / 7

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Planning of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 11

Gear pump units KFU2�40, KFU6�20, KFU2�64, electrically operated . . . . . . . . . . . . . . 12 / 13

Interconnected system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Piston pump PEF�90, pneumatically actuated . . . . . . . . . . . . . . . . . . . . . . 15

Electronic control and monitoring unit IG502�E . . . . . . . . . . . . . . . . . . . . . 16 / 17

Piston pumps PEF�90�S14, PEF�90�S19, PEF�90�S15,pneumatically actuated, for trailer and semitrailer lubrication . . . . . . . . . 18 / 19

Compact unit KFB(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 / 21

Piston distributor, group VKSO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 / 23

Fittings and auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24– 40

Topping up pumps for grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Connection of compressed air supply lineto vehicle network for a pneumatically actuated system . . . . . . . . . . . . . 42

Notice

All products from Willy Vogel AG may be used only for their intended purpose. If operatinginstructions are supplied together with the products, the provisions and information therein ofspecific relevance to the equipment must be observed as well.

In particular, we call your attention to the fact that hazardous materials of any kind, especiallythe materials classified as hazardous by EC Directive 67/548/EEC, Article 2, Par. 2, may onlybe filled into VOGEL centralized lubrication systems and components and delivered and/ordistributed with the same after consultation with and written approval from Willy Vogel AG.

All products manufactured by VOGEL are not approved for use in conjunction with gases,liquefied gases, pressurized gases in solution and fluids with a vapor pressure exceeding nor�mal atmospheric pressure (1013 mbars) by more than 0.5 bar at their maximum permissibletemperature.


Alphabetical index of subject

PageAdapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Banjo fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Body washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Bolts and screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Bracket for systems with KFU gear pump units . . . . . . 30

Cable harness for systems with KFB(S) compact unit . . . . . . . . . . . 21

Cable harness for systems with KFUS2�64 gear pump units . . . . . . 37

Cable harness for systems with KFU2�40, KFU6�20 gear pump units . . . . . . . . . . . 38

Cable harness for systems with KFU2�40, KFU6�20 gear pump unitsfor use on vehicles carrying hazardous goods . . . . . . 39

Cable harness for systems with PEF�90 piston pump . . . . . . . . . . . 40

Cable strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Compact unit KFB(S), electrically operated . . . . . . . . . 20 / 21Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 / 28Connectors for VKSO distributors . . . . . . . . . . . . . . . . . 32Control unit IG502�E . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 / 17Control unit IG476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Corrugated hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Coupling socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Cross joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Distributors for grease systems . . . . . . . . . . . . . . . . . . . 22 / 23

Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Filler socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Fittings and auxiliary equipment . . . . . . . . . . . . . . . . . . . 24 � 40Fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Fixing brackets for mounting of distributor . . . . . . . . . . 29

Gear pump units KFU2�40, KFU6�20, KFUS2�64 . . . 12 / 13

Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Hoses sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Interconnected system . . . . . . . . . . . . . . . . . . . . . . . . . 14

Lock washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PageMounting base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Mounting clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Overflow valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Piston distributor, group VKSO . . . . . . . . . . . . . . . . . . . 22 / 23Piston pump PEF�90, pneumatically actuated . . . . . . . . 15Piston pump

PEF�90�S14, pneumatically actuated PEF�90�S15, pneumatically actuated PEF�90�S19, pneumatically actuated . . . . . . . . . . . . . 18 / 19

Plastic tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Plug�in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Pressure curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Protective helix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Protective hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Pulse counter, mechanical . . . . . . . . . . . . . . . . . . . . . . . 19Pulse valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Pump fastening plate . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Reinforcing sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Screw plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Screw unions for steel and plastic tubing . . . . . . . . . . . 24Self�tapping screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Socket unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Spacer ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Steel tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 / 7

Tapered sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Tee connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Topping�up pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Trailer and semitrailer lubrication

with PEF�90�S14, PEF�90�S15 or PEF�90�S19piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 / 19

Tube cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24


Systems overview

Lubricant: Grease up to NLGI grades 000, 00 or 0 *

Selectioncriteria

Typedesignation

Pump

Type of drive

Operating pressure

Reservoir capacity

Lubricant distribution

Main lineconnection: pump � distributor

Mainly plastic tubing 10 x 1.5 diam., but also steel tubing 10 x 0.7 diamhose SLH10�…

Mainly plastic tubing 4x 0.85 diam.;in case of large movement between lubrication point and chassis: hose 734 …

Secondary lineconnection: distributor � lube point

Control system

Pump suitable for

Max. connected load (ccm)or

max. number of lube points80 ccm

Truck tractor

Truck tractor with extra equipment

Interconnected system/semitrailer

KFU units also for GGVS vehicles 1)(with cable harness 997�000�374)

electric

38 bars

2.7 liters

VKSO piston distributors

Electronic control unit IG502�E with or without monitoring function

KFUS with integrated control unit IG490

Gear pump unit

KFU2�40KFUS2�64

page 12

KFU6�20

6 liters

Technicaldata

Auxiliaryequipment

For progressive systems for commercial vehiclesup to NLGI grade 2 see leaflet 1�9430�US.

1) GGVS – Hazardous Goods Road Ordinance


.

Truck tractor

Truck tractor with small extraequipment

also for GGVS vehicles 1)(with solenoid valve DVS3206�E�F�S1)

Trailer/semitrailer

also for GGVS vehicles 1)

Electronic control unit IG502�Ewith or without monitoring function

with built�in electronic control unitIG476�2 for PEF�90�S14IG476�3 for PEF�90�S19

mech. pulse counter PEF�90�S15

page 15 page 18 page 20

Piston pump

PEF�90Compact unit

KFB(S)1

pneumatic

22 to 50 bars

3 liters

pneumatic

22 to 50 bars

3 liters 1.4 liters

VKSO piston distributors VKSO piston distributors

36 ccm

Truck tractor with small number of lubrication points

Truck tractor with extra equipment

also for GGVS vehicles 1)

approx. 20 lubrication points36 ccm

electric

30 bars

for GGVS�vehicles 1)

Piston pump

PEF�90�S14 / PEF�90�S15PEF�90�S19

* NLGI grade 0 at temperatures above –10 °C

Electronic control unit IG502with or without monitoringfunction

plastic tubing ø 10x1.5

plastic tubing ø 4x 0.85 diam.


Lubricants

The installed centralized lubrication system must only be operated with grease of NLGI grades 000, 00 within the intendedtemperature range of –25 °C to +80 °C.When grease of NLGI grade 0 is used, a restricted temperature range of –10 °C to +80 °C applies.

To ensure faultless operation of your centralized lubrication system at all times we recommend use of the grease listed below andtested by us. (Sodium�soap greases must not be used on motor vehicles due to their solubility in water.)

In the interest of a well functioning system always pay attention to cleanliness when topping up lubricant. Dirt leads to mal�functions of the centralized lubrication system and to destruction at the lubrication points.

When the listed products are used it is possible to change from conventional to biodegradable grease (and vice versa.) with no incon�venience.

A suitable grease conforming to the identicalspecifications of WILLY VOGEL AG,Mercedes�Benz AG and MAN AGcan be purchased from WILLY VOGEL AGin 1 kg and 25 kg drums.

1 kg drum, order No. FL1�000 1) 4)25 kg drum, order No. FL25�000 2)

Biodegradable types of grease availablefrom WILLY VOGEL AG can also be used in VOGEL centralized lubrication systems.

1 kg drum, order No. FL1�000BIO 1)25 kg drum, order No. FL25�000BIO 2)

Further types of grease, NLGI grades 000, 00:

Supplier Type

ARAL AG . . . . . . . . . . . . . . . . . . . . . Fließfett NAutol�Werke GmbH . . . . . . . . . . . . . Autol GetriebefließfettZSAAVIA Mineralöl AG . . . . . . . . . . . . . . AVIALITH 000 EPAxel Christiernsson . . . . . . . . . . . . . Acinol 8300�EPCSBP Oil Deutschland GmbH . . . . . . . Energrease ZS 00Calypsol . . . . . . . . . . . . . . . . . . . . . . SF 7�042Castrol Ltd., England . . . . . . . . . . . . Castrol CLS GreaseDEA . . . . . . . . . . . . . . . . . . . . . . . . . Dealit EP 00Deutsche Shell Gmbh . . . . . . . . . . . Shell Retinax CSELF . . . . . . . . . . . . . . . . . . . . . . . . . . MULTI BT 000Esso . . . . . . . . . . . . . . . . . . . . . . . . . Grease TCL 435FINA . . . . . . . . . . . . . . . . . . . . . . . . . MARSON ZS � G 0116Georg Oest Mineralölwerke . . . . . . . Oest Spezialfett LT 000 EPKompressol�Öl Verkaufs GmbH . . . . Kompressol CZ 8332/NKRAFFT . . . . . . . . . . . . . . . . . . . . . . KEC�GreaseMobil Schmierstoff GmbH . . . . . . . . Chassis Grease LBZMobil Schmierstoff GmbH . . . . . . . . Mobilgrease EAL 003MOL . . . . . . . . . . . . . . . . . . . . . . . . . Carrier Liton�00ÖMV � GmbH . . . . . . . . . . . . . . . . . . ÖMV�Signum EP ZOptimol . . . . . . . . . . . . . . . . . . . . . . . Olit 00Pluto . . . . . . . . . . . . . . . . . . . . . . . . . Plutoleum SHM 000Reiner Chemische Fabrik GmbH . . . Gearmaster ZSARHENUS . . . . . . . . . . . . . . . . . . . . . . Rhenus Norlith FZS 000Wilhelm Reiners GmbH & Co.Siebert GmbH . . . . . . . . . . . . . . . . . Fließfett EP 7028Texaco . . . . . . . . . . . . . . . . . . . . . . . Multifak 6833 EP 00Veedol Int. Ltd., England . . . . . . . . . Veedol GFGWintershall AG . . . . . . . . . . . . . . . . . Wiolub LFK 00Zeller+Gmelin GmbH & Co . . . . . . . Divinol Fett Central 00

Types of grease, NLGI grade 0 3):

Supplier Type

ARAL AG . . . . . . . . . . . . . . . . . . . . . Fließfett AN 0BP Oil Deutschland GmbH . . . . . . . BP Energrease ZS 0DEA Mineralöl AG . . . . . . . . . . . . . . . DEALITH EP 0Zeller+Gmelin GmbH & Co . . . . . . . Divinol L 0

Further biodegradable types of grease, NLGI grades 000, 00:

Supplier Type

ARAL AG . . . . . . . . . . . . . . . . . . . . . ARALUB BAB 000ASEOL . . . . . . . . . . . . . . . . . . . . . . . VIVA 4�131AVIA Mineralöl AG . . . . . . . . . . . . . . AVIALITH 000 BioAxel Christiernsson . . . . . . . . . . . . . Acinol 7302 BDBechem . . . . . . . . . . . . . . . . . . . . . . Bio�VE�8 00/000BP Oil Deutschland GmbH . . . . . . . Biogrease EP 00/000DEA . . . . . . . . . . . . . . . . . . . . . . . . . Dolon E EP 00Deutsche Shell GmbH . . . . . . . . . . . Shell Retinax CSB 00FINKE Mineralölwerk . . . . . . . . . . . . AVIATICON FETT BD�ZSAFuchs Lubritech GmbH . . . . . . . . . . Stabyl ECO 00Fuchs Petrolub AG . . . . . . . . . . . . . . Plantogel 0202 SÖMV�GmbH . . . . . . . . . . . . . . . . . . . ECODUR EP 00RHENUS . . . . . . . . . . . . . . . . . . . . . . Rhenus Norlith BZS 000Wilhelm Reiners GmbH & Co.Willy Vogel AG . . . . . . . . . . . . . . . . . Volvo grease 00CSBDTexaco . . . . . . . . . . . . . . . . . . . . . . . Multifac 264 EP 00/000Texaco . . . . . . . . . . . . . . . . . . . . . . . STARFAK EP 00Westfalen AG . . . . . . . . . . . . . . . . . . Bio�Gresalit�ZSA 00Wintershall AG . . . . . . . . . . . . . . . . . Wiolub LFB 00 BioZeller+Gmelin GmbH & Co . . . . . . . Divinol Biofett E 00

Biodegradable types of grease, NLGI grade 0 3):

Lieferant Sortenbezeichnung

ARAL AG . . . . . . . . . . . . . . . . . . . . . ARALUB BAB EP 0AVIA Mineralöl AG . . . . . . . . . . . . . . Syntogrease 0BP Oil Deutschland GmbH . . . . . . . Biogrease EP 0Fuchs Petrolub AG . . . . . . . . . . . . . . Plantogel 0201 SRHENUS . . . . . . . . . . . . . . . . . . . . . . Norlith BZS 0Siebert GmbH . . . . . . . . . . . . . . . . . Bio�Fließfett EP 4905

1) Coupler for 1 kg drum, Order No. KFU2.U82) Topping�up pumps for 25 kg drum, Order No. 169�000�082 and 169�000�0843) For units with grease pressurizer4) Filler bend for pumps with screw cover, order No. 169�000�037


Systems for grease up to NLGI grades 000, 00 or 0

�� Electrically operated gear pump units KFU / KFUS

�� Pneumatically actuated piston pump PEF�90

�� Electrically operated piston pump KFB(S)1

1. Planning and installation

a) Determination of number of lubrication points.All friction points of the chassis and any body units, with the exception of the universal joints of the cardan shaft.

b) Determination of metered quantities.The tabular values correspond to the average lubricant needs of the bearings in a vehicle weighing more than 8 tons.The lubrication frequency depends on the type of operation.

Truck tractors Metered qty Trailers and semitrailers Metered qty Buses Metered qty(ccm) (ccm) (ccm)

1. steering knuckle 0.4 1. tow bar 0.4 1. stop lever 0.12. spring pin 0.4 2. turntable (fifth wheel) 0.4 2. dual lever 0.13. spring suspension 0.4 3. spring pin 0.4 3. reversing lever 0.14. brake shaft 0.2 4. brake shaft 0.2 4. idler arm 0.15. brake shaft, wheel side 0.1 5. brake shaft, wheel side 0.1 5. linkage setting device 0.26. linkage setting device 0.2 6. linkage setting device 0.2 6. brake shaft 0.27. stabilizer 0.2 7. hand brake 0.1 7. brake shaft, wheel side 0.18. driver’s cab support 0.1 8. spare wheel 0.1 8. steering knuckle 0.49. longitudinal control arm 0.2 9. brake shoe pin 0.1 9. turntable 0.4

10. transverse control arm 0.2 10. steering assembly 0.4 10. drag link 0.411. coupling 0.1 11. support arms 0.1 11. knuckle pin bearing 0.412. gas control 0.1 12. wearing plate 0.4 12. axle support 0.413. center bearing 0.4 13. gas control 0.114. fifth wheel support plate 0.4

c) Calculation of system capacity

Maximum values:

Electrically operated gear pump unitsKFU / KFUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 80 ccm

Pneumatically actuated piston pumpPEF�90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 36 ccm

Electrically operated compact unitKFBS ...... Cf. diagram on page 20 for max. system capacity

Example of how to calculate the system capacity: *)

20 lubrication points, 0.4 ccm each . . . . . = 8 ccm10 lubrication points, 0.2 ccm each . . . . . = 2 ccm10 lubrication points, 0.1 ccm each . . . . . = 1 ccm

11 ccm+25% (safety margin) . . . . . . . . . . . . . . . . = 2.75 ccm

Compressibility and expansion losses:

1 ccm/m main�line tube(average value for steel and plastic tubing),assumed:12 m main�line tubing, 10 x 1 . . . . . . . . . . . = 12 ccm

Total **) 25.75 ccm

*) The example applies only to KFU and PEF�90 units. The safety margins for the KFB(S) units are already worked into the diagram.

**) If the calculated system capacity exceeds the capacity of the pumpunit, a second pump unit must be used. A second unit is also requiredwhen the vehicle is operated for extended periods of time at tempera�tures below –20 °C with a main�line train of more than 17 m.

d) Selection of distributors

Metered quantities of VKSO distributors: 0.1, 0.2 and 0.4 ccm.Depending on tubing layout: 2�, 4� and 6�port VKSO distribu�tors.Two different distributors are connected to one manifold with aVKR 2.U2 connector.

e) Tubing connections

Main line connections to VKSO distributors:

M16x1.5 thread for 10 mm diam. tube, tapped for solderlesstube connection.

Secondary (lubrication) line connections

to VKSO distributors: with plug�in connectors.


f) Installation

(Detailed installation instructions are available on request.)

This information is supposed to be a guideline and aid for thefitter. It will enable him to install the equipment on vehicles onhis own, even if there are no tubing layouts available, or onlyincomplete ones.

For the prevalent, standard types of commercial vehicleswe have prepared tubing layouts according to which theinstallations are to be made. If required, these layouts willbe mailed free of charge.

Additional superstructures and special vehicles can be out�fitted on the basis of these layouts.

The preassembled VKSO distributors for standard systemsare supplied with a preset metered quantity, but they can bechanged to another quantity of lubricant if necessary.

Install the VKSO distributors at suitable locations on the vehicle and connect to the tubing.

Max. length of the secondary lines(connection: distributor � lubrication point) 6 m.

Tighten the socket unions, but do not overtighten (maximumof 1½ turns). The tapered sleeves and tubing are slightlydeformed when tightened, thus offering no resistance – as afixing bolt would when tightened.

Attention must be paid to the following when installing thesecondary lines:

– Steering lock angle, sagging, chafing spots.

– Keep away from heat sources.

Install the pump and control unit at a suitable place.

Connect hoses and make electrical connections.

Some installation hints:

– Use the existing holes drilled in the chassis and in other vehicle parts for the installation.

– Span large boreholes with body washers.

– Lay 4 x 0.85 plastic tubing (as per WVN716, flexible) betweendistributors and lubrication points.

– Use 734...�K hose lines to connect non�stationary lubricationpoints and lubrication points that are subject to heavymechanical stress and strain.

– The compressed air for the PEF�90 pneumatically actuatedpump must be taken from a line for auxiliary loads. The regulations of the TÜV (Technical Control Board) must beobserved.

• The pertinent Hazardous Goods Road Ordinance (GGVS)must be observed in the case of tank trucks and othervehicles carrying hazardous goods.

The following can be used:

electrically operated gear pump units KFU2�40, KFU6�20in conjunction with cable harness 997�000�374; compact units KFB(S) in conjunction with cable harness 997�000�630 or 007�000�650

or

pneumatically actuated piston pump PEF�90 in conjunc�tion with solenoid valve DVS3206�E�F�S1.

Furthermore, the pressure switch line must likewise be laid incorrugated tubing.

2. Operation and maintenance

In the case of automatically controlled systems, with the excep�tion of KFB(S) compact units, the indicator light goes on forabout 3 seconds every time the ignition is switched on. (Seepoint 3 for response to malfunctions.)

For the most part, maintenance is limited to topping up withclean lubricant in good time.

All tube connections should be checked for a tight fit when thevehicle is inspected.

Replace torn or worn hose lines after eliminating the cause, andtrigger test lubrication. Actuate automatic systems by hand andobserve the indicator light.

The main line (connection: pump � distributor) is monitored by apressure switch that reports the build�up of pressure. Exception:KFBS and KFUS units. If the indicator light does not light up, or ifit burns constantly in the case of automatic systems, this meansthe pressure has failed to build up.

Select a smaller metered quantity for highly overlubricated pointsand a higher quantity for dry points.If the entire system is overlubricated or underlubricated, there isa malfunction: in this case proceed in accordance with 3.b) or3.c) respectively.

3. Malfunctions and their elimination

a) Fault indication by indicator light.

The indicator light does not go out about 3 seconds afterthe ignition is switched on or the motor started.

Look for the fault in the following order:

Check lubricant level in the reservoir;top up lubricant if necessary and bleed the system.

In the case of electrically operated gear pumps, loosen thescrew union of the main line while the pump is running. Theremust be a continuous discharge of lubricant.

In the case of pneumatically operated systems:

Check the compressed�air supply.Minimum pressure is 6 bars.

Check pump function.The piston stroke must be heard or felt when the compressedair is applied.

Check lubricant pressure in main line.Loosen the lubrication�point connection and check whetherthe distributor is delivering lubricant. If it is, the fault must belooked for in the pressure switch, electrical wiring or controlunit.

Please note:The distributor will not feed lubricant until the main line isrelieved of pressure again. It is therefore called a “relubricationdistributor”.

Check electrical connections:Is power available?Are all terminals tight?Check the indicator light, solenoid valve, pressure switch andcontrol unit.

Main line connections,main hose lines in particular, must be checked for leakage.Then check whether the pump valves are dirty.


b) Entire system insufficiently lubricated.

Install a pressure gauge in the main line and check the pressure build�up and relief. Min. pressure build�up is 30 bars.A maximum residual pressure of 1 bar may remain after thepressure is relieved (measured at pump's outlet port).

c) Entire system is overlubricated.

Check setting of control unit and increase interval time if necessary.

d) Individual lubrication points are overlubricated or under�lubricated.

Change metered quantity.

e) Distributor faults.

Replace distributors.

Please note!

Absolute cleanliness must be maintained when doing anywork on the system, especially when replacing metering nip�ples on distributors. Dirt in the system causes malfunctions.

Never use trichloroethylene, perchloroethylene or similar liquids aggressive to Perbunan when cleaning centralizedlubrication systems.Suitable cleaning agents are petroleum ether or kerosene.

Pressure curve in main line in the case of systems with VKSO relubrication distributors

Pneumatically actuated piston pumps and electrically oper�ated gear pump units have the same pressure characteristic,but the time required for the pressure build�up will generally beshorter with pneumatically actuated piston pumps.

The maximum pressure reached in the main line depends on theactuating pressure of the piston pumps or on the pressure inten�sity of the safety valve in the case of gear pump units.

Pneumatically operated piston pumps: . . . . . . . . . . 22�50 bars

Electrically operated KFU.. gear pump units: . . . . . . ≈ 38 bars

Electrically operated KFBS compact units: . . . . . . . . . ≈ 30 bars(length of main line limited to 10 m)

Functional sequence

At the end of the preset interval time, the pump motor isswitched on and the pressure required by the system built up.This is reported to the control unit by the actuation of the pres�sure switch. At the end of the pump running time the pumpmotor is switched off and a new interval time begins.

If there is no signal from the pressure switch while the pump is inoperation, the control unit reports a fault at the end of the pumprunning time. This is signaled by the constant burning of the indi�cator light.

The metering chambers of the distributors are filled with lubricantduring the pressure build�up in the main line.

The relief of pressure in the main line via the pressure relief valvestarts when the pump is switched off. The lubricant from themetering chambers is delivered to the lubrication points by thespring�loaded distributor pistons at the same time as the pres�sure is relieved.

The KFB(S) compact units have the same functional sequence,but the pressure build�up is not monitored in this case.

lubrication cycle (also work cycle time)

start of distributor feed

pressure build�up time*)

pressure retention time

pressurerelief time

max. residual pressure 1 bar(measured at pump outlet port)

feeding time of distributors

pump running time interval time

Time

Lub

rica

nt p

ress

ure

in m

ain

line

0

*) depending on size of system and pump


The gear pump unit consists mainly of a gear pump with reliefvalve, safety valve, DC motor, transparent lubricant reservoir, fillersocket and angle bracket. The DC motor and filler socket arecovered by a hood to protect them from dirt. The hood snapsinto place on both sides of the reservoir lid.

Function

The gear pump continuously supplies lubricant to the relubrica�tion distributors via the main line network when the pump is inoperation. As soon as the metering chambers of the distributorsare full the excess lubricant flows back into the reservoir via thesafety valve.

At the end of the pump running time (start of the interval time),the pressure relief valve opens so that the pressure in the mainline can drop to a residual pressure of 0.2 to 1.0 bar. The spring�loaded pistons of the distributors can now deliver lubricant fromthe metering chambers to the lubrication points.

Nearly every size of system on commercial vehicles, includingsuperstructures, can be supplied by one single pump when aKFU2�40 or KFU6�20 pump unit is used.

Furthermore, the semitrailer or trailer can be connected in theform of an interconnected system, but this is only advisablewhen the motor vehicle and semitrailer/trailer are rarely or neverdisconnected from each other.

The KFU units must be used with cable harness 997�000�374on vehicles approved for the transport of hazardous goodsby road (GGVS).

Associated cable harness for KFU, order No. 997�000�373; cable harness for KFUS2�64, order No. 997�000�750.

Technical data

Order No. . . . . . . . . . . . . . . . . . KFU2�40 . . . . . KFU6�20Order No. . . . . . . . . . . . . . . . . . KFUS2�64reservoir capacity . . . . . . . . . . 2.7 l . . . . . . . . . 6 l

Weight (without lubricant) . . . . . ca. 5.5 kg . . . . ca. 7.3 kg

operating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . .12 or 24 V DCPlease quote required voltage when ordering.

12 V fuse for KFU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,5 A24 V fuse for KFU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,5 A

12 V fuse for KFUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 A24 V fuse for KFUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 A

flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 ccm/minat back pressure p = 38 bars and temperature t = 25 °C

system capacity for single�line systems . . . . . . . . . . max. 80 ccm

units with relief valve and safety valvemax. operating pressure . . . . . . . . . . . . . . . . . . . . . . . 38 +2

�3 bars(corresponds to actual value of built�in safety valve)

permissible operating temperature . . . . . . . . – 25 °C to +75 °C

type of enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP 59 k

lubricant . . . . . . . . . . . . grease up to NLGI grades 000, 00 or 0NLGI grade 0 at operating temperatures above –10 °C.

Associated control unit for KFU: IG502�E,KFUS unit with integrated control unit: IG490.

Gear pump units KFU2�40, KFU6�20, KFUS2�64 with reservoir, electrically operated

Hydraulic layout

main line tosystem

filler socket

safety valvepressure relief valve


Gear pump units KFU2�40, KFU6�20, KFUS2�64 with reservoir, electrically operated

1) Coupling bush for filler socket, order No. 995�001�500 (please order separately).2) The cover must be removed for filling. Press in cover with both hands at the positions

marked and lift.3) Ports tapped for solderless tube connection.

This unit should only be used for systems with a minimum lubricant consumption of 6 l /year.

el. connection for2�pole plug connector M24x1with polarity reversal protection

connection portfor main line

to system

overfill andventing tube

transparent reservoir

filler socket 1)

KFU2�40 with 2.7 l reservoir

KFU6�20 with 6 l reservoir

pushbutton for intermediate lubrication

overfill andventing tube

el. connection 4�pole

quick connectorfor main line

KFUS2�64 with 2.7 l reservoir

Dim

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The unit is installed on the truck tractor, and the main line of thefollowing vehicle is connected to the centralized lubricationsystem of the truck tractor via a plug and socket coupling.

The feed capacity is dimensioned so that all standard inter�connected vehicles can be supplied.

The units must be used with cable harness 997�000�374 onvehicles approved for the transport of hazardous goods byroad (GGVS).

Associated control unit: IG502�E

Interconnected system with KFU2�40, KFU6�20, KFUS2�64 gear pump units, electrically operated,for truck tractors with trailer or semitrailer without frequent change of vehicles

Coupling parts for interconnected system

Coupling parts Complete, Parts for trailer or semitrailerfor interconnected system but with spiral tubing 1) with spiral tubing 1)

Order No. 181�123.01 Order No. 181�122.01 Order No. 181�140.01

1) Spiral tubing , order No. 167�003�501

*) Please order separately if required

to centralized lubricationsystem of truck tractor

from unitKFU2�40KFU6�20

angle bracket881�250�004with borehole ø17

cap898�630�000

plug898�630�002

dummy plug *)to protect socket when disconnected

hose shell screw union406�710�002 410�313406�810�002

connectorDAR510

washer to centralized827�200�006 lubrication system

of trailer or semitrailer

plug 833�170�005cap 898�630�000nut DIN936�M14x1.5washer 650�140

parts for truck tractor, parts for trailer or semitrailerorder No. 181�128.01 Order No. 181�129.01

tee piece main line ø10 *) plug socket hose lineDAT510 995�000�818 995�000�819 WVN711�10, 3000 mm long

(for 2�axle trailer, 4000 mm long)

*)

{

��

�


The unit consists mainly of

– a lubricant pump in the form of a pneumatically actuated piston pump with spring reset,

– suction valve,

– combination pressure and relief valve,

– lubricant reservoir in the form of a bellows, including protectiveholder,

– filler socket for topping up the lubricant reservoir..

Function

The delivery piston is moved in the direction of the outlet afterpressurization with compressed air. As a result, the lubricant that flowed into the pump chamber through the suction valve isdelivered to the system via the combination pressure and reliefvalve.

After the compressed air is switched off the delivery piston isreturned to its initial position by the reset spring. Due to theresulting underpressure the combination pressure and reliefvalves also returns to its initial position, thereby opening thepressure relief bore; the pressure in the main line is relieved as a result.

Due to the pressure relief the paths from the metering chambersto the friction point are opened in the distributors so that thespring�loaded metering pistons can now deliver lubricant to thefriction point.

The inlet valve is opened by the underpressure resulting from thereturn motion of the piston, and new lubricant flows into thepump chamber.

This ends the work cycle.

Please noteWhen filling for the first time, overfill the pump unit in order tokeep air from becoming trapped in the bellows and to assurefaultless operation.

Technical data

Order No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PEF� 90delivery rate per stroke . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ccmoperating pressure (depending on air pressure) . . 22 to 50 barsmax. perm. P1 air pressure for the pump . . . . . . . . . . . . 10 barspermissible operating temperature . . . . . . . . . –25 °C to +80 °Creservoir capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 l lubricant . . . . . . . . . . . . . . . grease of NLGI grades 000, 00 or 0

NLGI grade 0 at operating temperatures above –10 °C.

materials:cylinder/piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Al Mg Si 0.5valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . steel, Cu Zn 40 Pb 2seals, lubricant reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . NBRmounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . as shownWeight (without lubricant) . . . . . . . . . . . . . . . . . . . approx. 4.7 kg

Make sure the pump is installed without distortion!

Associated control unit: IG502�E

Piston pump PEF� 90, pneumatically actuated

P1P2

R

Hydraulic layout

protectiveholder

overfill opening

lubricantreservoir

air inlet

lubricant outlet

filler socket

P1 = when connected to tubing:adapter 406�054 for 6 mm diam. tubing,order washer 508�108 separatelycan be connected to 3/2�way solenoid valve DVS3206�E�F

P2 = ports tapped for solderless tube connection for tube ø10

See page 41 for grease topping�up pumps.

P1 = air line from compressed air networkP2 = main line of system

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Operating and display elementsThe IG502 control units come with an operating and displaypanel that can be used to check, monitor and, if necessary, readjust the parameters as well as programmed functions.

Modes of operationPAUSE (pump OFF) with timer function– programmable from 0.1 to 99.9 h– digital display after invoking: tPA (t = timer, PA = PAUSE)

The PAUSE (the interval between two lube cycles) is determined by a

clock cycle (timer) generated by the control system and by the value (in

hours) programmed for PAUSE (tPA).

PAUSE (pump OFF) with counter function– programmable from 1 to 999 pulses– digital display after invoking: cPA (c = counter, PA = PAUSE)

The PAUSE (the interval between two lube cycles) is determined by the

interval between the times signals arrive at the counter input and by the

value programmed for PAUSE (cPA).

CONTACT (pump ON) with timer function– programmable from 1 bis 99.9 minutes– digital display after invoking: tCO (t = timer, CO = CONTACT)

The pump running time (CONTACT) is determined by a clock cycle

(timer) generated by the control system and by the value (in minutes)

programmed for CONTACT (tCO).

Monitoring functions

PS (Pressure Switch)

This monitoring function is intended for centralized grease lubri�cation systems designed for NLGI grades 000, 00,0 in which thepressure in the main line is monitored. Once the monitoringparameter PS has been programmed, the pressure switchinstalled in the main line is monitored for respective signals whilethe pump is in operation.

CS (Cycle Switch)

This monitoring function is intended for centralized grease lubrication systems with progressive feeders in which a piston'smotion is monitored with a cycle switch.

Once the monitoring parameter CS has been set, the cycleswitch installed on the progressive feeder is monitored for therespective signal while the pump is in operation.

The respective monitoring parameter selected (PS or CS) is displayed by the lighting of the corresponding LED in the PAUSE(interval) mode.

Without monitoring (OFF)

The monitoring can also be switched off (OFF).

The control system then works without direct monitoring of thepressure build�up in the main line or without monitoring of thefeeder's operation. The PS or CS LEDs do not light up.

Fault displays

The red FAULT LED shows a group fault signal when it constantlyburns. The cause of the fault signal is additionally shown on thedigital display to help with troubleshooting.

The following messages are provided for:

FPS – pressure build�up fault when monitoring is effected with apressure switch.

FCS – cycle�switch fault when a progressive feeder is not work�ing or is blocked (line break).

Special functions

Control units comprising the IG502 group have two electroniccounters in which times are permanently stored; they cannot bechanged by the user.

These counters are used to check the operation of the centralizedlubrication system and are read out via the LED display.

Fault�hours counter

The amount of time a farm or construction machine has been runwith a non�functioning centralized lubrication system (e.g. withno lubricant in the reservoir) is added up by the fault�hourscounter.

The counter's contents are automatically updated and cannot becleared. The current state of the counter can be displayed byinvoking function parameter Fh on the display and operatingpanel. The current value is displayed in hours.

The counter has a resolution of 0.1 hour, i.e. the smallest display�able interval amounts to 6 minutes.

Elapsed�hours counter

The electronic elapsed�hours counter adds up the time in whichpower is applied to the control unit.

The counter's contents are automatically updated and cannot becleared. The current state of the counter can be displayed byinvoking function parameter Oh on the display and operatingpanel. The current value is displayed in hours.

The counter has a resolution of 0.1 hour, i.e. the smallest display�able interval amounts to 6 minutes.

The units comply with the legal requirements of EC Directives

– 72/245/EEC, version 95/54 EC– 89/336/EEC

Application

The IG502�E universal control unit is used to control and monitorcentralized lubrication systems on commercial vehicles. The con�trol unit's functions can be programmed. Its housing dimensions,electrical connection and functions are compatible with those ofVOGEL control units in use to date.

The operating elements are protected by a foil against moistureand dirt. The unit has a voltage�independent data memory. Thisis where the configuration data and parameters are stored. As aresult, the control unit is not dependent on a constant supply ofvoltage.

If an external indicator light SL has been installed in the driver'scab, it will light up for 3 seconds after the unit is switched on.

Installation

The unit has to be installed in a closed compartment on the vehicle where it is protected from ambient influences. It is fastened in place with straps.

The IG502�E is accommodated in an IP 20 type of enclosure.The plug conforms to safety class IP 00.

If the control unit is installed in a hard�to�reach place, it is advis�able to additionally install an illuminated pushbutton on the dash�board to serve as a fault display and function check.

Electronic control unit IG502�E for systems with KFU2�40, KFU6�20 gear pump units or PEF�90 piston pumps


Technical data

Order No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG502�E

Associated cable harness for KFU2�40, KFU6�20 . . . . . . . . . . order No. 997�000�373for KFU2�40, KFU6�20for vehicles with hazardous goods . . order No. 997�000�374for PEF�90 . . . . . . . . . . . . . . . . . . . . order No. 997�000�189

control votlage 1) . . . . . . . . . . . . . . . . . . . . . . . . . 12 or 24 V DCmax. contact load, terminal M . . . . . . . . . . . . . . . . . . . . . . . 5 ASL�output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Wtype of enclosure 2) . . . . . . . . . . . . . . . . . . . . . IP 20, DIN 40050temperature range . . . . . . . . . . . . . . . . . . . . . . . . –25 to +75 °Cmax. fusing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Aprogrammable interval times . . . . . . . . . . . . . . . . . 0.1 to 99.9 hprogrammable pump running time . . . . . . . . . . 0.1 to 99.9 minprogrammable pulses . . . . . . . . . . . . . . . . . . . . . . . . . . 1 to 999elapsed�time, fault hours memory . . . . . . . . . . . 0 to 99999.9 h

1) Please quote control voltage when ordering.2) Warranted for vertical (plug�in connector pointing downward) and

horizontal installation.

Wiring diagram

(time axis not to scale)

tu = ignition interruptionts = contact timetp = interval time

30 = battery + / vehicle network15 = operating voltage + / after ignition “ON”31 = operating voltage –DK/MK = pushbutton / intermediate lubrication or pulse�counter inputPS/CS = pressure switch / cycle switch M = pump motorSL = indicator lightZ = ignition lockF = 5 A fuse

LED PAUSEllights in intervals.

LED CONTACTlights when pump running.

LED CSlights for monitoring with cycle switch function.

LED PSlights for monitoring with pressure switch function.

LED FAULTlights for fault monitoring (cycle or pressure switch).

Normal functional sequence

Dim

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Trailer and semitrailer lubrication

with PEF�90�S14 pneumatically actuated piston pump including IG476�2 electronic control unitwith PEF�90�S19 pneumatically actuated piston pump including IG476�3 electronic control unitfor use on vehicles carrying hazardous goods

with PEF�90�S15 pneumatically actuated piston pump including DSWM21�2�S1 mechanical pulse counter

Diagram of a system

overflow valve 232�100�001(overflow pressure 6 bars)

filler socket

Technical data of piston pumpssee PEF�90 page 15

compressedair tank

3/2�way pulsed valve995�800�166

electr. control line fromstop�light switch

IG476�2 electronic control unit

20�240brakeapplic.

weight (without lubricant): approx 11.4 kg

P1 = compressed air connection portP2 = pressure port to system

for PEF�90�S19with corrugated tube(used on vehicles carrying hazardous goods)

electronic control unit(PEF�90�S14PEF�90�S19)

exhaust line

pulsed valve compl.order No. 995�800�166

PEF�90�S15 with 3/2�way solenoid valveorder No. DVS3206�E�F

Rear view of PEF�90�S19 Rear view of PEF�90�S15Rear view of PEF�90�S14PEF�90�S. .

Functional sequencePEF�90�S14, PEF�90�S19 with electronic control unit IG476

The switching pulses for the stop light are registered and addedin the electronic control unit at an interval of at least one second.As soon as the preset number of brake applications is reached,the pulse�controlled 3/2�way solenoid valve is energized for alubricating time of at least 40 seconds, thereby pressurizing thecompressed air cylinder of the piston pump. The delivery pistonof the pump executes one working stroke, the lubricant distribu�tors are filled (relubrication distributors).

Application of the brakes during the lubricating time is ignored.

The first application of the brakes at the conclusion of the lubri�cating time reverses the valve. As a result, the compressed aircylinder of the piston pump is relieved of pressure, and the deliv�ery piston returns to its initial position. At the same time, thisrelieves the pressure in the main line so that the distributors cannow deliver the lubricant.

Further applications of the brakes are now registered and addedagain.

The control unit is equipped with an EEPROM memory that storesthe counter states, even when no power is applied betweenapplications of the brakes.

The number of times the brakes have to be applied before lubri�cation takes place depends on the conditions in which the vehicleis operated. It is possible to set the number of times (20, 40, 60,80, 100, 120, 140, 160, 180, 200, 220, 240) after which lubricationis initiated. After changing the setting it is advisable to triggermanual lubrication so that the counter begins at 0 again.

The unit is set at the factory for 100 applications of the brakes.

A pushbutton is built in for function tests when the brakes areapplied. The function test can only be performed when there isadequate air pressure (more than 6 bars) in the air tank andpower is available!

Functional sequence PEF�90�S15 with DSWM21�2�S1 mechanical pulse counter

Every time the stop light switch is actuated, the 3/2�way�soleno�id valve is energized and compressed air delivered to the coun�ting mechanism of the pulse counteer. When the specified num�ber of brake applications set with the pulse counter is reached(cf. adjustment table), the compressed air is switched to thecylinder of the piston pump. The delivery piston of the pumpexecutes one working stroke, the lubricant distributors are filled(relubrication distributors).

After further application of the brakes (max. of 6 times with rat�chet drive set to one tooth), the compressed air is switched offagain and the delivery piston of the pump returns to its initialposition. At the same time, the centralized lubrication system isrelieved of pressure so that the distributors can now supply lubri�cant to the friction points.

The number of times the brakes have to be applied before lubri�cation takes place depends on the conditions in which the vehi�cle is operated.

To perform a function test, unscrew the screw plug (Pg9) in thecover and turn the pin wheel to the left with a screwdriver – untiltripped. Then screw the plug in again. The function test can onlybe performed when there is adequate air pressure (more than 6bars) in the air tank.

Adjustment table

number of operating strokes required untilpins valve is actuated with ratchet driveinserted 1 tooth 3 teeth

1 96 322 48 164 24 8

Changing the setting

1. Set hexagonal nut for adjustment of ratchet drive to desireddrive – the embossed number indicates the number of teethper drive; possible: 1 tooth or 3 teeth per drive.

2. Unscrew cover.3. Remove disk from pin wheel.4. Insert required number of pins (max. 4).5. Place disk on pin wheel and screw on cover, check function.


Trailer and semitrailer lubrication

with PEF�90�S14 pneumatically actuated piston pump including IG476�2 electronic control unitwith PEF�90�S19 pneumatically actuated piston pump including IG476�3 electronic control unitfor use on vehicles carrying hazardous goods

with PEF�90�S15 pneumatically actuated piston pump including DSWM21�2�S1 mechanical pulse counter

IG476�2

black�lilac = VAbrown = VE

brown (31)

black�lilac (54)

box for pins not in use

compressed air connection port in front 3/2�way solenoid valve

to piston pumpplug�

�

� �

�

�

�

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The KFB/KFBS compact unit consists mainly of a gear pumpwith DC gear motor, relief and safety valve, control unit, pushbut�ton for manual triggering and lubricant reservoir.

The lubricant reservoir comes with an overfill release valveand vent. The filling level can be seen in the reservoir made oftransparent material. The reservoir is filled via a filler coupling..

The lubricant supplied by the pump is distributed to the indi�vidual lubrication points via VKSO piston distributors.

Piston pump Reservoir capacity order No. [liters] Grease filling

KFB11.4 via filler socket

KFBS1 (incl. control system)

with filling�level monitoring function

KFB1�W1.0 via filler socket

KFBS1�W (incl. control system)

with preinstalled 4�port piston distributor

KFB1�4�S...1.4 via filler socket

KFBS1�4�S... (incl. control system)

with preinstalled 6�port piston distributor

KFB1�6�S...1.4 via filler socket

KFBS1�6�S... (incl. control system)

Order examples see page 21.

The KFBS pump unit is controlled by the integrated IG502�I con�trol and monitoring unit. This can be done on a time or (pulse)load�dependent basis, with or without monitoring of the system'spressure build�up. A pressure switch1) has to be installed in thesystem for this purpose.

Technical Data

Unitoperating voltage . . . . . . . . . . . . . . . . . . . . . . 12 VDC / 24 VDC

(please indicate when ordering)

Mode/ON time . . . . . . . . . . . . . . . . . . . . . . . . S3 / 4% – 60 min.Pay attention to interval and contact time when setting!

Max. runtime 2.5 min., min. interval time 1 hoperating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 barpermissible operating temperature . . . . . . . . –25 °C to +75 °CDIN 40050 enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP 6K9Knumber of outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1weight (filled with grease) . . . . . . . . . . . . . . . . . . approx. 3.8 kglubricant . . . . . . . . . . . . . . . grease up to NLGI grade 000, 00, 0system capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cf. diagrammain line . . . . . . . . . . . . . . . . . . . . . . . . 10x1.5 diam.; max. 16 m

cf. diagram

Function

The automatic cycle consisting of the interval time and pumprunning time is started after the KFB/KFBS unit has been connected to the vehicle’s electrical system and the ignitionturned on.

When the ignition is on, the pump motor is switched on at theend of the interval time and the pump running time started.During the pump running time the gear pump delivers lubricantfrom the reservoir to the metering chambers of the relubricationdistributors. As soon as the metering chambers of the distribu�tors are full the surplus lubricant flows back into the reservoir viathe safety valve.

Forced pressure relief is initiated at the end of the pump runningtime (beginning of the interval time), the pressure in the distributorfeed (main line) drops to a residual pressure of 0.2 to 1 bar viathe open relief valve. The spring�loaded pistons of the distribu�tors can now deliver lubricant from the metering chambers to thelubrication points.

A new interval time sequence is started when the pump motor isswitched off.

The interval time stops running down every time the ignition isswitched off. The interval time continues to run down when theignition is turned on again.

All further lubrication operations are repeated on a cyclic basis inthe order described.1) Pressure switch for 20�bar switching pressure, order No. DS�E20�S1

(when installed at end of main line); for 25�bar switching pressure, order No. DS�E25�S1 (not possible wheninstalled at end of main line).

Associated cable harness for pressure switch, order No. 997�000�379.

KFB/KFBS compact unit, electrically operated

Diagram: max. system capacity / max. length of main linefor NLGI grades 000, 00

Diagram: max. system capacity / max. length of main linefor NLGI grade 0

�m

ain

line

(m)

� system capacity of distributors (ccm) � system capacity of distributors (ccm)

�m

ain

line

(m)

Range of application Range of application

KFBS1


KFB/KFBS compact unit, electrically operated

KFB1 without control unit

Pin allocation KFB1 Cable harness 997�000�706 (not included in delivery)

Pin No. Function Core color

1 15 plus potential red/black

2 31 minus potential brown

Pin allocation KFB1�W / KFBS1(�W) Cable harness 997�000�904 (not included in delivery)(for GGVS design 2): 997�000�630 or 997�000�650)


1 31 minus potential brown2 15 plus potential red/black3 DK manual lubrication blue4 SL2 indicator light, ext. pink5 ZDS+ pressure switch, +output black6 ZDS pressure switch, input black7 SL1 status display light purple/green

2) GGVS = Hazardous Goods Road Ordinance

Hydraulic layout

safety valve

relief valve

filler socket

KFBS1 with control system KFB1�4�S... with preinstalled piston distributor

See above for missing dimensions and data.

transparent reservoir

pressure switsch

filler socket

4�pole circularconnectorConnection for cable harness

7�pole circular connectorConnestion for cable harness

pressure switch

port No. 1

piston distributorVKSO4

filler socket 1)*) Ports tapped fpr solderless tube connection for 10 mm diam. tube.1) Coupling bush for filler socket, order No. 995�001�500 (order separately).

The voltage key has to be added to the order No: 12 V DC: order key 91224 V DC: order key 924

Order example for compact unit without distributors: KFB1 in 24 VDC, order No. KFB1+924

Order example for compact unit with 4�port piston distributor: KFB1 in 24 VDC with VKSO4. metered with 0.2; 0.2; 0.2; 0.2 ccm (as of port 1)order No. KFB1�4�S1+924 (specified with same metering of 0.2 ccm)

Order example for compact unit with 6�port piston distributor: KFB1 in 12 VDC with VKSO6, metered with 0.1; 0.4; 0.2; 0.2; 0.4; 0.1 ccm order No. KFB1�6�S..+912 (specified after receipt of order)D

imen

sion

s in

mm


The distributors meter and distribute the lubricant from the pumpto the individual lubrication points. They do so independent ofeach other.

Interchangeable metering nipples make it possible to adapt thequantity to the amount of lubricant required by the friction point.

The cycle number, i.e. the number of pump strokes per time unitof the lubrication system, also permits further coordination of thelubricant quantity with the friction point and entire system.

Lubricant is only delivered under spring pressure after the end ofpump operation, i.e. after the pressure is relieved.

A collar (changeover valve) in the distributor closes the outlet tothe lubrication point during the delivery stroke, thus storing thelubricant beneath the piston. The changeover valve opens theoutlet as soon as the pressure drops in the main line, i.e. whenthe pressure relief valve of the pump opens.

When installing a system, arrange the lines and distributors insuch a way that any air entrained in the system can escape byitself via the lubrication points. For this purpose, distributors withhorizontal outlet ports or with outlet ports pointing upward mustbe installed at a position suitable for bleeding of the entire sys�tem.

Assign only one lubrication point to each distributor outlet port.

Connect the secondary line (connection: distributor � lubricationpoint) to the lubrication points only after bubble�free lubricantemerges from the tubing after the pump is repeatedly actuated.Fill long secondary lines beforehand if necessary.

The metered quantity can be seen from the shape of the meter�ing nipple and code number.

Piston distributors, group VKSO (relubrication distributors)

Design and function

Metering nipples

Distributor in initial position Distributor pressurized Distributor feedingsystem is non�pressurized main line pressurized by pump main line relieved of pressure

VKSO2

VKSO6

VKSO4

Max. delivery pressure of relubrication distributors13.5 bars independent ofpump feed pressure

metering nipple

piston spring

piston

O�ring

main line plug�in connector

collar withsupport ringvalve spring valve clearance

to lubricationpoint�

� �

�

0.1 0.2 0.4 ccm


Piston distributors are only supplied with metering nipplesfitted.

Plug�in connectors permit timesaving installation of secondarylines without the use of tools (cf. page 26).

Order No. number of lubrication points

VKSO2 … 2VKSO4 … 4VKSO6 … 6

When ordering distributors, please quote the desired meteredquantities (0.1; 0.2; 0.4 ccm) in the respective order.

Metering nipples, with O�ringfor metered quantity Order No.

0.1 cm3 VKU010�K0.2 cm3 VKU020�K0.4 cm3 VKU040�K

Distributors are connected to manifolds with a connector,order No. VKR2.U2

connector

↑↑Individual distributor outlet ports can be closed with plug pin450�204�002 and thus shut down. Other metered quantities will not beaffected by this step.

Piston distributors, group VKSO (relubrication distributors)

metering nipple

VKSO2 ... 2�port distributor



1) Quick connector connection for ø4 plastic tubing.2) Ports tapped for solderless tube connection.

M16x1,5 for 10 mm diam. tube, M8x1 for 4 mm diam. tube.

1 2 3 4

0,2

If required:←←screw plug 410�011washerDIN7603�A16 x20�CU

Dim

ensi

ons

in m

m


Fittings and auxiliary equipment

Adapters with tapered thread for screwing into lubrication ports without sealing face

for outer tube diam. Order No. d1 d2 L1 L2 sw

4 404�662K M6 tap. M8x11) 19 5 114 404�663K M6 tap. M8x11) 20 6 114 404�673K M6x0.75 tap. M8x11) 20 6 114 404�047K M7 tap. M8x11) 20 6 114 404�003K M8x1 tap. M8x11) 17 7.4 114 404�045 M8x1 tap. M8x11) 62.5 7.4 114 404�006K M10x1 tap. M8x11) 16 7.4 114 401�004�512 M10x1 tap. M8x1 25 7.4 114 404�050 *) M8x11) 18 5.2 114 853�460�000 *) M8x11) 46 5.2 114 404�040K R1/8 tap. M8x11) 16 6 114 404�040K�US 1/8 NPTF M8x11) 20 6.7 114 404�054K R1/4 tap. M8x11) 14 9 144 404�072 1/4�28 UNF M8x11) 20 5.6 114 401�004�903 1/4 BSF M8x11) 20 5 114 401�004�904 3/16 BSF M8x11) 18 5 114.5 406�004K�S1 M10x1 M10x11) 23 7.4 134.5 406�004K�S2 M10x1 tap. M10x1 18 7 134.5 456�004K�S2 R1/8 tap. M10x1 18 6 134.5 401�019�691 R1/8 tap. G1/8 23 7.5 146 406�004K M10x1 tap. M10x11) 23 7.4 146 406�035K M10x1 tap. M10x1 40 8 14

Adapters with tapered threads areused without washers, since taperedthreads are self�sealing. Therefore,the ports do not have to be providedwith sealing faces.

Material:steel, galvanized surface

1) Ports tapped for solderless tubeconnection

2) Tapered thread according to DIN 158,tapered, short, or as per DIN 2999

*) Self�forming thread for 7.6 mm diam.borehole

Screw unions for steel and plastic tubing(use reinforcing socket for plastic tubing)

Reinforcing socket Taperedfor plastic tubing sleeves Socket unions

for outertube diam. Order No. Order No. Order No. d1

4x0.85 404�603 404�611 404�612�MS M8x16x1.25 406�613 406�611 406�612�MS M10x18x1.25 408�603 408�611 408�612�MS M14x1.5

10x2 *) 410�613 410�611 410�612�MS M16x1.5

Material: brass *) Mercedes Benz version

AssemblySlide socket union and tapered sleeve onto end of the tube.In the case of plastic tubing, first insert the reinforcingsocket. Insert end of tube into tapped port up to the stop.First tighten the socket union finger�tight and then turn itanother 11/2 turns.

Adapters with respective washers

for outer Adapter Washertube diam. Order No. d1 d2 L1 L2 sw Order No.

4 404�044 *) M8x1 M8x1 46 6 11 DIN7603�A8x11.5�CU4 404�063 M8 M8x1 22 8 11 DIN7603�A8x11.5�CU4 404�006 M10x1 M8x1 18 7.5 14 504�0194 404�007 M10x1 M8x1 24 6 11 504�0194 404�164 M14x1.5 M8x1 18 9 17 DIN7603�A14x18�CU 6 406�004 M10x1 M10x1 18 7.5 14 504�019 6 406�166 M16x1.5 M10x1 19 9 19 DIN7603�A16x20�CU6 406�054 G1/4 A M10x1 20 10 17 508�1088 408�004 M10x1 M14x1.5 28 7.5 17 504�0198 408�005 M16x1.5 M14x1.5 22 9 19 DIN7603�A16x20�CU8 301�020 G1/4 A M14x1.5 23 10 17 508�108

Material

Adapters:steel, galvanized surface

Washers: copper

Please note!Order washers separately!

1) Ports tapped for solderless tubeconnection

*) extra long

1)

1)

2)

tapped port reinforcing socket(for plastic tubing)

tapered sleeve

socket union



Adapters

for outertube diam. Order No. L1 L2 L3

4 404�004 24 14 64 404�005 32 22 5

Material: steel, galvanized surface1) Ports tapped for solderless tube connection

Elbows with tapered threadfor screwing into lubrication ports without sealing face.Elbows with tapered threads are used witout washers, sincetapered threads are self�sealing. Therefore, the ports do not haveto be provided with sealing faces.

for outertube diam. Order No. d1

4 504�200K M6 tap.4 504�201K M8x1 tap.4 504�202K M10x1 tap.4 514�018K�S1 R1/8 tap.

Material: brass

for outertube diam. Order No.

4 504�211K

Material: brass


4 504�050

Material: steel, galvanized surface

1) Ports tapped for solderless lube connection.2) Tapered thread according to DIN 158, tapered, short, or as per DIN 2999.

Elbow

Order No. d Type

406�145K M8x1 tap. A406�045K M10x1 tap. A406�089K M8x1 tap. B406�090K M10x1 tap. B


Screw plugsand respective flat washers

Screw plug Flat washersOrder No. d1 Order No.

404�011 M8x1 DIN7603�A8x11.5�CU408�011 M14x1.5 DIN7603�A14x18�CU410�011 M16x1.5 DIN7603�A16x20�CU

Material: steel, galvanized surface Material: copperPlease note!Order flat washersseparately!

Self�forming thread for7.6 mm diam. borehole

A B

Pin plug for plug�in connector, tube diam. 4

Order No. 450�204�002

Material: brass

Dim

ensi

ons

in m

m

Banjo fittings

Elbow type

for outertube diam. Order No. d1 d 2 1)

4 504�401 M8x1 M8x16 506�140 M10x1 M10x16 506�214 G1/4 A M10x16 506�145 M16x1.5 M10x18 508�145 M16x1.5 M14x1.5

10 510�024 G1/4 A M16x1.510 510�145 M16x1.5 M16x1.5

L�type

for outertube diam. Order No. d1 d 2 1) d 3 1)

4 504�114 M8x1 M8x1 M8x16 506�114 M10x1 M10x1 M10x16 and 10 506�346 M16x1.5 M10x1 M16x1.5

10 and 8 508�346 M16x1.5 M14x1.5 M16x1.510 510�343 G1/4 A M16x1.5 M16x1.510 510�344 M16x1.5 M16x1.5 M16x1.510 and 6 510�346 M16x1.5 M16x1.5 M10x1

Banjo fittings, freely movable

for outertube diam. Order No. d1

4 405�549�049 M8x1 tap.4 405�551�049 M10x1 tap.

Swing angle: 360°Frequency: approx. 1 movement/min. at max. swing angle

1) Ports tapped for solderless tube connection



Plug�in connectors, detachable

Adapters

Order No. tube diam. d d1 L

451�004�462�VS 4 M6 tap. 25.8451�004�498�VS 4 M8x1 tap. 23.3451�004�518�VS 4 M10x1 tap. 22.8

Banjo fittings

Order No. tube diam. d d1 ø d2 L1 sw

455�546�048�VS 4 M6 tap. 10 6 10455�529�048�VS 4 M8x1 tap. 10 6 10455�531�048�VS 4 M10x1 tap. 10 6 12

Elbows

Order No. tube diam. d d1 ø d2 L1 L2

453�004�471�VS 4 M6 tap. 10 6 14504�201�VS 4 M8x1 tap. 10 6 13.5504�202�VS 4 M10x1 tap. 10 6 13.5

514�018�VS 4 R1/8 tap. 10 7.5 15

Protective cap for quick connectors, 4 mm diam. tubing,order No. 898�110�077.

Pipe cutter with formation of claw groove for quick connectors,order No. 169�000�336.

washer

banjo union

banjo bolt

banjo bolt

banjo union

washer

washer

banjo bolt

banjo union

washer

washer



Connector, tube to tube

for outertube diam. Order No. d1 d2 1) d3 1) L1 L2 sw

4 404�008 M14x1.5 M8x1 M8x1 27 19 174 404�009 * M14x1.5 M8x1 M8x1 38 30 176 406�008 M14x1.5 M10x1 M10x1 30 20 178 408�008 M20x1.5 M14x1.5 M14x1.5 40 28 24

10 410�008 M20x1.5 M16x1.5 M16x1.5 42 27 24

Material: steel, galvanized surface* specially long version for double frame.

for outer tube diam. Order No.

4 504�103

Material: brass


4 404�010


for quick connectors


4 454�504�041�VS

for outer tube diam. Order No.

4 504�004 1 fastening hole4 504�040 2 fastening holes

Material: die�cast zinc

for outertube diam. Order No. d 1)

6 DAR506 M10x18 DAR508 M14x1.5

Material: aluminum alloy

for outertube diam. Order No. d1 1) d 2 1)

10 DAR510 M16x1.5 M16x1.58 and 10 DAR510�S1 M14x1.5 M16x1.5



ø4 t

ube

ø4 t

ube

Dim

ensi

ons

in m

m



Connectors, tube to tube

Double connector


4 DAR524


Triple connector


4 DAR534


Tee

for outertube diam. Order No. d1 1) d2 L1 L2 h h1 h2

6 DAT506 * M10x1 6.6 22 40 30 9 208 DAT508 * M14x1.5 6.6 32 50 40 9 29

10 DAT510 ** M16x1.5 7 25 52 40 15 29

Material: * aluminum alloy; ** steel, galvanized surface


Tee


10 (2x) and 8 (1x) DAT510�S1


Tee


4 504�045

Material: die�cast zinc

Cross joint


10 DAK510�S1


30

5 13

M8x

11)

6.6

6 13

25

20

1522

30

ø12

24

6 14

M8x

11)

6.4



Fixing brackets for mounting of distributors

Order No. 881�260�020


Order No. 881�280�006


Order No. 881�280�007


Order No. 881�280�008 Order No. 881�280�009


Order No. 881�290�110


Order No. 881�290�111


R3.53530

50

7

29

83

15

15

3

9

4014

25

11.5

7

12

10

7.5 25

3

25

80 R4R4

6 4860

17.52

31

1425

11.5

7

7

1512

32

Dim

ensi

ons

in m

m



Pump fastening plate for systems with KFU gear pump units and PEF piston pumps

Order No. 995�002�140

Bracket for systems with KFU gear pump units

Order No. 881�290�450

square tube



Fixing bolts

Hexagonal head bolts

Order No. L b k sw e

DIN933�M6x20�8.8 20 20 4 10 11.1DIN933�M6x25�8.8 25 25 4 10 11.1DIN931�M6x30�8.8 30 18 4 10 11.1DIN933�M6x35�8.8 35 35 4 10 11.1DIN931�M6x40�8.8 40 18 4 10 11.1DIN933�M6x45�8.8 45 45 4 10 11.1DIN931�M6x55�8.8 55 18 4 10 11.1DIN933�M8x25�8.8 25 25 5.5 13 14.4DIN933�M8x35�8.8 35 35 5.5 13 14.4


Self�tapping screws

Order No. l d1 d 2

DIN7981�B4.2x9.5 9.5 4.2 8.2DIN7981�BZ4.8x9.5 9.5 4.8 9.5DIN7981�BZ4.8x13 13 4.8 9.5


Lock washers

Order No. for bolt d1 d 2 s h

650�050 BZ 4.8 5.3 9 0.6 0.9650�060 M6 6.4 10 0.7 0.9650�080 M8 8.4 13 0.8 1.2650�140 M14 15 22 1.2 1.8650�160 M16 17 24 1.3 1.9650�200 M20 21 30 1.5 2.2

Material: spring steel

Body washers

Order No. d1 d 2 s

821�400�006 6.6 28 2821�400�010 8.4 30 1.5


Mounting base

Order No. 179�990�186

Nuts

Order No. d1 m sw e

DIN934�M6�8 M6 5 10 11.5DIN934�M8�8 M8 6.5 13 14.4DIN936�M14x1.5�5 M14x1.5 8 22 25.4DIN936�M16x1.5�5 M16x1.5 8 24 27.7DIN936�M20x1.5�5 M20x1.5 9 30 34.6


self�stick foil

Dim

ensi

ons

in m

m



Spacer ring

Order No. 898�210�061

Material: CR (chloroprene rubber)

Connector for VKSO distributors

Order No. VKR2 . U2

Cable strap

Order No. L b

898�610�000 197 4.9898�710�000 302 4.9898�710�001 360 7.5

Material: polyamide

For automatic pincers:

single part

Order No. 898�510�002 898�510�000

Material: polyamide

Mounting clips

for outer for outertube diam. D Order No. L tube diam. Order No.

4 604�001�A 9 4 604�1116 606�010�A 108 608�001�A 12

10 610�001�A 13

Material: mild steel, galvanized surface

for outer Number tube diam. Order No. of tubes

4 604�002�A 2

Material: mild steel, galvanized surface

for outertube diam. D Order No. d b L

6 941�206�104 5.2 15 116 941�206�108 6.4 18.5 14.28 941�208�104 6.4 18.5 15.29 941�209�104 5.2 15 12.5

12 941�212�104 6.4 18.5 17.213 941�213�104 6.4 18.5 17.715 941�215�104 6.4 18.5 18.717 941�217�104 5.2 15 16.520 941�220�104 6.4 18.5 21.222 941�222�100 6.4 18.5 22.227 941�227�104 10.2 31 31

Clip with cushion

lubricationlines

brakehose

spacer ringcablestrap

corrugatedtube

rubber profile

separating cut

double tapered sleeve



Tubing

Steel tubing, galvanizedminimum bending radius rbent with bent with

Order No. da s di mandrel grooved disk

WV�RO4x0.7VERZI 4 0.7 2.6 6 –WV�RO6x0.7VERZI 6 0.7 4.6 22 16WV�RO8x0.7VERZI 8 0.7 6,6 42 22WV�RO10x0.7VERZI 10 0.7 8.6 71 27

Diesel injection pipe

DIN73000A2�6ST30AL 6 2.0 2.0 22 16

Plastic tubing WVN715, unplasticized/semi�rigid as per DIN 73 378

perm.minimum operating rupturebending pressure pressure

Order No. da s di radius r (bars) (bars)

WVN715�RO10x1.5+A89 10 1.5 7 89 40 120

Color: black

Plastic tubing WVN716, flexible as per DIN 73 378

perm.minimum operating rupturebending pressure pressure

Order No. da s di radius r (bars) (bars)

* WVN716�RO4x0.85 4 0.85 2.3 38 36 109WVN716�RO6x1.25 6 1.25 3.5 63 35 106

* The WVN716�RO4x0.85 plastic tubing can be supplied in various colors and also filledwith grease NLGI grades 000, 00 or 0.

The following color key information to be added to the order No. applies in this case:

Color keyColor key tubing filled with grease

A 87 = green AF 1 = natural colorA 88 = red AF 4 = brownA 89 = black AF 6 = blackA 90 = brown AF 7 = redwithout color key: natural color AF 8 = green

Order examples

Plastic tubing WVN716�RO4x0.85, color black, 5 m long:Order No. WVN716�RO4x0.85+A89, 5 m

Plastic tubing WVN716�RO4x0.85, color green, filled with grease, NLGI�Klasse 000, 00 or 0 ,8 m long:

Order No. WVN716�RO4x0.85+AF8, 8 m

Use screw unions withreinforcing socketsfor plastic tubing

Dim

ensi

ons

in m

m



External Socket unionL + 5 Order No. tube diam. Hose diam. thresd

580 SLH10�580650 SLH10�650 10 14 M16x1.5

1600 SLH10�1600

Material inner liner: PA 11/12 oder PE�Ereinforcement: 1 layer of braided, highly tear�resistant synthetic fiberouter cover: PA 11/12

Please order tapered sleeves 410�611 and socket unions 410�612�MS separately.

ExternalL + 5 Order No. tube diam. Hose diam. d3

220 734�220�K260 734�260�K

4 8.8 M8x1300 734�300�K340 734�340�K

Complete with socket unions and double tapered sleeves

Material hose: oil�proof rubber inside and outside with braided rayon carcass.tube ends: steel tube, tube ends permanently bonded to the hose.

l + 5 Order No. Hose diam.

580 774�58012.9960 774�960

Material protective hose: polyamide PA 6plastic tubes: polyamide PA 11 or PA 12, flexible

4 colors: green, black, red, brown

Order No. di s a

982�760�061 4 1 10 Please indicate length982�760�121 8.5 1.5 10 (up to 25 m) when ordering

Material: soft polyethylene, color: black

Order No. rated width da x s di L *)

982�760�070 4 7 x 1,25 4 up to max. 100 m *)

982�760�120 8 11.7 x 1.6 8.4982�760�130 10 12.9 x 1.5 10 up to max. 50 m *)982�760�160 12 15.7 x 1.7 12.3

Material: polyamide 6; color: black *) please quote when ordering

Hose sleevesfor protective hose 982�760�130(rated width 10)

Order No.2�hole:898�210�047

3�hole:898�210�075

4�hole898�210�063

Hoses for main lines(connection: pump � distributor)

Hoses for secondary lines(connection: distributor � lubrication point)

Please note!These hoses line must not be used asmain hose lines

Multiple�line hoses(connection: distributor � lubrication point)

Protective helix

Protective hose

double taperedsleeve

socket union

l



Tube cutter

Order No. 169�000�301

Spare cutting wheel

Order No. 844�300�001

Filler socket

Order No. 995�000�705

Respective coupling socket order No. 995�001�500

Coupling socket for topping�up port

Order No. 995�001�500

Respective plug order No.. 833�370�001

Connection piece with hose socket, ND 16order No. 857�870�002

Coupler for grease drum FL1�000

Order No. KFU2.U8

Shears for plastic tubing

Order No. 169�000�090

Tube cutter with formation of claw groove for 4 mm diam. quick tube connectors

Order No. 169�000�336

Cutting wheel

Order No. 844�330�006

Dim

ensi

ons

in m

m



3/2�way solenoid valves

for mounting on the pump: order No. DVS3206�E�F

Type of enclosure IP 56 a

Associated coupler socket, order No. 179�990�091

Technical data of valves

passage at valve seat . . . . . . . . . . . . . . . . . . . . . . . . 2 mm diam.air�flow rate at 6 bars . . . . . . . . . . . . . . . . . . . . . . . . . . 200 l/minmax. air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 barsswitching frequency . . . . . . . . . . . . . . . . . . . . . . . . . ca. 250/minvoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 / 24 V DC

(please quote when ordering)

power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . ca. 12 W

mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . as shown

complete with protective hose and screw unionfor GGVS *) vehicles

Order No. DVS3206 �E�F�S1

Type of enclosure IP 56 a

Associated coupler socket, order No. 179�990�296

*) verhicles carrying hazardous material

1) The magnet can be turned to any position after nut is loosened.2) Coupler socket with interference suppression circuit.

Overflow valve without return flow

Order No. 232�100�001

operating pressure . . . . . . . . . . . . . . . . . . . . . . . . max. 10 barspermissible medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . airtemperature range . . . . . . . . . . . . . . . . . . . . – 40 °C to + 80 °Crated width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mmoverflow pressure 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 bars

1) The secondary units are not supplied until a pressure of more than 6 barsreached in the main tank.

protective hose7 m long

air

tank

Pulse valve

Please note:: Use the pulse valve only with control unitsIG476�2 and IG476�3.

Order No. 995�800�166

f. tu

be

ø6

f. tu

be

ø6

f. tu

be

ø6



Indicator lights

for MAN verhicles and Mercedes�Benz buses

Order No. 179�100�028

Indicator light fitted with filament lamp (order No. 179�100�026).Spare filament lamp, order No. 179�100�054.

for Mercedes�Benz trucks

Order No. 179�100�025

Indicator light fitted with filament lamp (order No. P�66.62).Please indicate 12 V or 24 V voltage when reordering.

for Scania trucks

Order No. 179�100�070

This includes: base, order No. 179�990�3302 receptacles, order No. 179�990�331

for general needs

Order No. Face Voltage Power

P�66.60GRUEN greenP�66.60ROT red 12 or 24 V 2 WP�66.60GELB yellow

Spare filament lamp

P�66.62 12 or 24 V 2 W

Please indicate 12 V or 24 V voltage when ordering.

Pressure switch

Order No. switching pressure (bars)

DS�E20�S1 20 ± 2,5

DS�E25�S1 25 ± 2,5

connection for 4 mm prongscontact rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 W at 24 Vtemperature stability . . . . . . . . . . . . . . . . . . . . – 25 °C to +80 °Ctype of enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP 56 atype of contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . NO contact

The diaphragm is restistant to mineral oils.

Coupler socket, Order No. 179�990�098

Coupler socket for corrugated tubeOrder No. 997�000�376

Coupler socket

cable gland

twin coupling for4 mm prong

SW22Flachstecker 6,3x0,8

M17

x1.5

26.5

~36.5

Tab 6.3x0.8

Cable harness 12 m – 2�core typefor system with KFUS2�64 gear pump unit

Pin allocation


1 – 31 brown2 + 15 red/black

Order No. 997�000�750

tap

.

Dim

ensi

ons

in m

m



Cable harness for systems with KFU2�40, KFU6�20 gear pump units

Order No. 997�000�373

groundbrown, 2 m

indicator lightpink, 2.5 m

terminal connector(supplied detached)

pushbutton ormachine contactblue, 2 m

housing for A.M.P. tabs

coupler socketmotor

flat tab receptacles(supplied detached)

ignitionred / black, 2 m

electric line topressure switch

grey + black,2�core, 9 m

electric line to motor, 2�core

black�lilac / browndouble sheathed, 9 m

coupler socketpressure switch

Cable harness, consisting of:

1 housing for A.M.P. tabs 179�990�0766 flat tab receptacles 179�990�0772 flat tab receptacles 179�990�0792 flat tab receptacles 179�990�2792 terminal connections 179�990�0901 cable plug 179�990�0821 coupler socket (DS) 179�990�0981 connector shell 179�990�2722 plug sockets 179�990�2641 plug cap 898�320�023 Motor connection1 socket union 847�420�0061 washer 824�400�004

Cable 1.5 mm 2

single�sheathed 981�900�008double�sheathed, 2�core 981�900�018 for pressure switchdouble�sheathed, 2�core 981�900�031 for motor

terminal connections

Connection terminals for the

control unitIG502�E

}



Cable harness for systems with KFU2�40, KFU6�20 gear pump unitsused on vehicles carrying hazardous goods

Order No. 997�000�374

groundbrown, 2 m


terminal connection(supplied detached)



branch



electric line to pressure switch


electric line to motor 2 �core

black�lilac / browndouble sheathed, 9 m

retaining clip

protective hose



1 housing for A.M.P. tabs 179�990�0766 flat tab receptacles 179�990�0772 flat tab receptacles 179�990�0792 flat tab receptacles 179�990�2792 terminal connections 179�990�0901 cable lug 179�990�0821 branch piece 898�520�0025 circlips 898�210�0761 socket (DS) 997�000�3761 socket (M) 997�000�3754 cable straps 898�610�0041 corrugated tube 11 m 982�760�120

Cable 1.5 mm 2, insulated 981�900�047

connector for pressure switch

connector for motor





Cable harness for systems with PEF�90 piston pump

Order No. 997�000�189

groundbrown, 2 m


terminal connection(supplied detached)







electric line to pushbutton


electric line to solenoid valve

2�coreblack�lilac / brown

double sheathed, 9 m

coupler socket



1 housing for A.M.P. tabs 179�990�0764 flat tab receptacles 179�990�0772 flat tab receptacles 179�990�0793 flat tab receptacles 179�990�2792 terminal connections 179�990�0901 cable lug 179�990�0821 coupler socket (DS) 179�990�098

Cable 1.5 mm 2

single�sheathed 981�900�008double sheathed, 2 �core 981�900�018 for pressure switchdouble sheathed, 2 �core 981�900�031 for solenoid valve

Topping�up pump without trolley

Order No. 169�000�084

Can be used for grease drum FL25�000FL25�000�BIO

max. internal diameter . . . . . . . . . . . . . . . . . . . 340 mmmax. height . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 mmcapacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 kgpump output . . . . . . . . . . . . . . . . 0.25 l / double stroke



Topping�up pump with trolley

Order No. 169�000�082

Can be used for grease drum FL25�000FL25�000�BIO

max. internal diameter . . . . . . . . . . . . . . . . . . . 340 mmmax. height . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 mmcapacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 kgpump output . . . . . . . . . . . . . . . . . 0.1 l / stroke ±10%

Operating instructions

Open the grease drum and place the cover of the topping�uppump on the drum.

Insert the suction tube in the opening in the cover, push down tothe bottom of the grease drum and secure with the lock screw.

Use a clean cloth to thoroughly clean the filler socket of the vehicle pump and filler coupling of the grease pump after remov�ing the protective caps.

Now connect the coupling of the topping�up pump to the fillersocket of the vehicle pump. The hose coupling must snap intoplace when connected.

Actuate the lever of the topping�up pump until the reservoir ofthe vehicle pump is filled to within approx. 1 cm of the topedge (max. marking on reservoir).

When the reservoir is full remove the coupling from the pumpand put the protective cap back on the filler socket.

Slip the coupling half of the topping�up pump onto the respectiveholder.

Coupling bush for topping�up connection order No. 995�001�500

Dim

ensi

ons

in m

m


For trailers with air suspension:

Air connection at the air tank for secondary line loadswith straight connector.

Order No.

Straight connector . . . . . . . . . . . . . . . . . . . . . 441�006�432Back�up ring . . . . . . . . . . . . . . . . . . . . . . . . . . 847�400�004O�ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 971�020�250

For trailers with air suspension:

Air connection at air tank for secondary loadsbranch of air connection with tee piece.

Order No.

Tee piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408�407Reducing connector . . . . . . . . . . . . . . . . . . . 408�406

For trailers with laminated leaf springs:

Air connection at the air tank with safety valve(without return flow).

Order No.

Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . 232�100�000Tee connector with test connection . . . . . . 491�900�001Straight connector . . . . . . . . . . . . . . . . . . . . . 441�006�432Back�up ring . . . . . . . . . . . . . . . . . . . . . . . . . . 847�400�004O�ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 971�020�250

Connection of compressed�air supply line to the compressed air system of a vehicle for a pneumatically operated centralized lubrication system

• Observe the regulations of the Technical Control Board (Tech�nischer Überwachungsverein) when connecting the air supplyfor the centralized lubrication system.

• The air supply line may only be connected to an air tank or toa line for secondary loads.

• The compressed air for the centralized lubrication system mustbe clean and dry.

The following check should be made to ascertain whether the airsupply line has been connected at a place conforming to thesafety regulations:

– Open the air line to the centralized lubrication system so thatthe air can escape. The air pressure indicated on the pressuregauge in the driver's cab must not drop below 5.5 bars; the airbrake pressure is thus maintained as prescribed.

to centralized lubrication system

tube ø6

straight connector

safety valve

back�up ringO�ring

tee connector withtest connection

air tank

air tank forsecondary loads

to centralizedlubrication system

tub

e ø

6

straight connector

back�up ringO�ring

reducing connector

to centralizedlubrication system

air tank forsecondary loads

tube ø6

tub

e ø

8

tee piece

Sub

ject

to

chan

ge w

ithou

t no

tice!

WN

00 0

2/20

04

Willy Vogel AGMotzener Strasse 35/3712277 Berlin, GermanyP.O.Box 970444 ·12704 Berlin

Tel. +49 (0) 30 �7 20 02�0Fax +49 (0) 30 �7 20 02�111info@vogel�berlin.dewww.vogelag.com

Willy Vogel AG2. Industriestrasse 468766 HockenheimGermany

Tel. +49 (0) 62 05 � 27�0Fax +49 (0) 62 05 � 27�132info@vogel�berlin.dewww.vogelag.com

Vogel France SASRue Robert Amy, B.P. 13049404 Saumur cedexFrance

Tel. +33 (0) 241 404 200Fax +33 (0) 241 404 [email protected]

Documents

Singleline Systems for Commercial Vehicles - Mekol · for use on vehicles carrying hazardous goods ... Singleline Systems for Commercial Vehicles for grease up to ... 4. brake shaft